Tubular plastic mounting panel for door hardware

ABSTRACT

A mounting panel is provided for mounting a window and a window regulator in a vehicle door. The mounting panel is comprised of a one-piece plastic molded member having a central planar mounting member adapted to mount the window regulator, and a plurality of spaced apart spokes molded integrally with the center drill plate and radiating generally forward and rearward therefrom to mount the guide channel receiving the edges of the window. The window guide channels are preferably integrally molded with the radiating spokes. The spokes are hollow tubular members of generally circular cross-section. The molded plastic mounting panel also has a plurality of integrally molded arm rest supports which project laterally therefrom and are adapted to support an arm rest structure of the vehicle door. The plurality of apertured mounting brackets are molded integral with the spokes for receiving fasteners by which the mounting panel is mounted on the vehicle door. The plurality of snap fasteners are integrally molded with the mounting panel for snap together fastening of such door operating hardware as the window regulator, the window regulator motor, door handle, and the door latch control rods.

This is a continuation of application Ser. No. 08/084,904 filed Jul. 02,1993, now U.S. Pat. No. 5,367,832 which is a continuation of 07/852,055filed Mar. 16, 1991, now U.S. Pat. No. 5,251,403.

The invention relates to a mounting panel for moving a window, a windowregulator, and a door handle in a motor vehicle door, and moreparticularly provides a one-piece molded plastic mounting panelcomprised of a plurality of spaced apart tubular spokes extendingbetween spaced apart window guide channels.

BACKGROUND OF THE INVENTION

The prior art has recognized the desirability of manufacturing a vehicledoor with the door hardware such as the window, the window regulator,and the door handles mounted on a panel to define a module which may bepreassembled and tested away from the vehicle assembly line.

The prior art has also recognized the desirability of manufacturing sucha door hardware module using a molded plastic construction for themodule panel in order to provide lightweight and economical manufacture.In order to provide a plastic mounting panel of adequate strength andrigidity, the prior art has recognized embedding metal tubes in theplastic module. The prior art has also recognized that the door modulepanel may be strengthened and stiffened by molding stiffening ribs inthe plastic module panel. In addition, the prior art has recognized thatthe window guide channel which guides the vertical movement of the glassmay be molded integrally with the window panel.

The present invention provides a new and improved molded plastic panelfor a vehicle door window and hardware module.

SUMMARY OF THE INVENTION

According to the invention, a mounting panel is provided for mounting awindow and a window regulator in a vehicle door. The mounting panel iscomprised of a one-piece plastic molded member having a central planarmounting plate adapted to mount the window regulator, and a plurality ofspaced apart spokes molded integrally with the center drill plate andradiating generally forward and rearward therefrom to mount the guidechannel receiving the edges of the window. The window guide channels arepreferably integrally molded with the radiating spokes. The spokes arehollow tubular members of generally circular cross-section. The moldedplastic mounting panel also has a plurality of integrally molded armrest supports which project laterally therefrom and are adapted tosupport an arm rest structure of the vehicle door. A plurality ofapertured mounting brackets are molded integral with the spokes forreceiving fasteners by which the mounting panel is mounted on thevehicle door. A plurality of snap fasteners are integrally molded withthe mounting panel for snap together fastening of such door operatinghardware as the window regulator, window regulator motor, door handle,and the door latch control rods.

The object feature and advantage of the invention resides in theprovision of a one-piece molded plastic door module mounting panelcomprised of integrally molded together tubular spokes extending betweenfront and rear window guide channels and mounting an integral plasticmounting plate for the window regulator.

A further object, feature and advantage of the invention resides in theprovision of a one-piece molded plastic mounting panel comprised ofradially spaced apart spokes and having integrally molded arm restsupports projecting laterally therefrom.

A still further object, feature and advantage resides in the provisionof a one-piece molded plastic mounting panel comprised of radiallyspaced part hollow tubular spokes and having support portions moldedthereto to mount the door operating hardware such as window regulator,door handle, and arm rest.

A still further feature of the advantage resides in the provision of aone-piece molded plastic mounting panel of hollow plastic tubularconstruction carrying integral apertured mounting brackets for receivingfasteners by which the mounting panel is mounted on a vehicle door.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, objects and advantages of the invention willbecome apparent upon consideration of the description of the preferredembodiment and the appended drawings in which:

FIG. 1 is a side elevation view of a door hardware module having theone-piece molded plastic mounting panel of this invention;

FIG. 2 is a partial plan view taken in the direction of arrows 2--2 ofFIG. 1;

FIG. 3 is a section view taken in the direction of arrows 3--3 to showthe mounting of a window regulator and a window regulator motor on themounting panel;

FIG. 4 is an enlarged fragmentary view of FIG. 3;

FIG. 5 is a section view taken in the direction of arrows 5--5 of FIG.1;

FIG. 6 is a section view taken in the direction of arrows 6--6 of FIG. 2and showing the mounting of door latch control rods in an integral snapfastener of the door panel;

FIG. 7 is a section view taken in the direction of arrows 7--7;

FIG. 8 is a section view taken in the direction of arrows 8--8 of FIG. 2showing snap together attachment of the inside door handle to themounting panel.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 is a side elevation view of a hardware module, generallyindicated at 10, for a vehicle door. The module 10 is comprised ofvarious door hardware elements mounted on a one-piece molded plasticmounting panel, generally indicated at 12. The mounting panel 12includes a front guide channel 14, and a rear guide channel 16 which areintegrally connected by a plurality of hollow tubular spokes, includingspokes 18 and 20 which radiate forwardly from a central vertical spoke21 to the front guide channel 14, and a plurality of spokes 22, 24, and26 which radiate rearwardly from the central vertical spoke 21.

Suitable molding process and equipment for molding the hollow tubularspokes is described in U.S. Pat. Nos. 4,740,150, 4,923,667, 4,824,732,4,923,666 and 4,498,860 owned by Cinpres Limited, Appollo House,Lichfield Road Industrial Estate, Tamworthy, Staffondshire B79 7TA,England.

The window guide channel 14 is generally C-shaped in cross section asviewed in FIG. 3 and includes a hemispherical base wall 30 and spacedapart channel walls 32 and 34. As best seen in FIGS. 1 and 2, thechannel wall 32 is defined by vertical spaced apart tabs 36 and thechannel wall 34 is defined by vertically spaced apart tabs 38. Thesetabs 36 and 38 are vertically staggered from one another so that themold halves in which the mounting panel 12 is molded can be pulled apartin the direction indicated by arrows A and B in FIG. 3. As seen in FIG.3, an elastomeric slide strip 39 is installed into the guide channel 14between the channel walls 32 and 34 to slidably receive the edge 41 of awindow panel 40.

As best seen in FIGS. 1 and 3, the mounting panel 12 includes agenerally planar window regulator mounting plate 50 which is anintegrally molded part of the mounting panel 12 and spans between thevertical spoke 21, the upper spoke 18 and the lower spoke 20. Themounting plate 50 is reinforced by a network of stiffening ribs 54 whichproject laterally from the mounting plate 50 and extend between thespokes 18, 20, and 21. The network of strengthening ribs 54 also definesa circular hub 60 having a bore 62 in which a metal pivot shaft 64 isrotatable. As seen in Figures 1 and 3, the pivot shaft 64 isnon-rotatably attached to a stamped steel window regulator lift arm 66of a window regulator generally indicated at 68. This attachment isobtained by a twist-lock projection 67 of the pivot shaft 64 whichextends into an aperture 69 of lift arm 66 as described further in U.S.Pat. No. 5,079,871.

As shown in FIG. 1, the lift arm 66 carries a slide 70 on the endthereof which rides in a sash channel 72 attached to the window panel 40by rivets 74 and 76. The window regulator 68 also includes a regulatorarm 80 which is pivotally connected to the lift arm 66 by a pivot 84.The regulator arm 80 has a slide 86 carried thereon which rides in thesash channel 72. The regulator arm 80 also has a slide 92 pivotallycarried on the other end thereof which rides in a slot 94 of themounting panel 12. This slot 94 is defined by integral webs of material96 and 98 which respectively project from the tubular spokes 24 and 26.

The mounting panel 12 also has integral features which enable themounting of a motor assembly 102 for operating the window regulator 68.As seen in FIG. 1, the motor assembly 102 includes a gear box 104 havingmounting lugs 106, 108 and 110 spaced around the circumference thereof.As seen in FIG. 3, the motor assembly 102 is positioned with the gearbox 104 juxtaposed with the face of mounting plate 50 and a pinion gear105 of the gear box 104 extending through an aperture 111 in themounting plate 50 to engage with a plurality of teeth 113 displayed onan arcuate sector 112 carried by the lift arm 66. The pinion gear 105 ismounted on shaft 114 which projects through a bore 116 provided in amounting arm 118 which is molded integral with the mounting plate 50.The motor assembly 102 is anchored against rotation by a cylindricalstud 122 which projects from the central plate 50 into a bore 24 in themounting lug 110 of the gear box 104. Similar mounting studs, not shown,project through similar bores provided in the mounting lugs 106 and 108of the gear box 104. The motor assembly 102 is fastened against removalfrom the mounting panel 12 by a resilient snap tab 130 which projectslaterally from the mounting plate 50 and has a undercut shoulder forengagement with the mounting lug 110 of the gear box 104. As seen inFIG. 1, additional snap tabs 134 and 136 are associated with themounting lugs 106 and 108. A pair of back up shoulders 142 and 144 aremolded integrally with the mounting plate 50 and project in spacedrelation behind the tab 130 to prevent over travel of the tab 130.Similar back up shoulders are provided behind the snap tabs 134 and 136.

As best seen in FIG. 4, it will be understood that the motor assembly102 is installed upon the mounting panel 12 by thrusting the gear box104 in the direction toward the mounting plate 50 so that the mountinglug 110 engages against a ramp face 150 of snap tab 130 and urges thesnap tab 130 radially outward. When the gear housing 104 reaches theposition of FIGS. 3, 4 and 5 engaging the plate 50, the snap tab 130returns to its position of FIG. 4 in which the undercut shoulder 132engages over the face of the mounting lug 110 of gear box 104. It willbe appreciated that the snap tabs 130, 134, and 136 are all similarlyconstructed and function to effectively attach the motor assembly 102onto the mounting panel 14.

As best seen in FIGS. 1 and 3, a counterbalance spring 156 acts betweenthe pivot shaft 64 and the mounting panel 12 to balance the weight orthe window panel 40. The counterbalance spring 156 is a spiral springand includes an inner end 158 anchored in a slot 160 of the pivot shaft64 and an outer end 162 which hooks over an abutment 164 moldedintegrally on the mounting panel 12.

As best seen in FIGS. 1, 2, and 8, a door handle 170 is also mounted onthe mounting panel 12. The handle 170 includes a hand grip 172 carriedon a goose neck 174 which is integral with a shaft 176. The shaft 176has pintles 178 and 180 projecting from the ends thereof. The mountingpanel 12 has an integral mounting plate 192 molded therewith and havingan opening 196 through which the handle 170 may be inserted in thedirection indicated by arrow C. During such insertion of the handle 170,the pintles 178 and 180 engage against and forcibly deflect lock tabs200 and 202 into a spaced apart position until the pintles 178 and 180are carried into engagement with journal defining walls 206 and 208which are molded integral with the mounting panel 12. The pintle 178reaches the installed position shown in FIGS. 2 and 8 in which thepintle is captured between the journal defining wall 206 and the springtab 200. The pintle 180 is similarly captured between the journal wall208 and the spring tab 202. The handle 170 is normally biased to therotary position shown in FIGS. 2 and 8 by a coil spring 220 seated on aspring seat 222 of the handle 170 and having a spring end 226 engagingwith the mounting panel 12 to urge the handle 170 to the normalposition.

The door handle 170 is connected to a door latch, not shown, by acontrol rod 232. Another control rod 234 is connected to a door lockhandle 236 pivoted on the mounting plate 12 and also extends to the doorlatch.

FIGS. 6 and 7 show a rod guide, generally indicated at 240, for slidablymounting the control rod 232. The rod guide 240 is molded integrallywith the mounting panel 12 and includes a cradle 242 having a recess 244which receives the control rod 232. As best seen in FIG. 6, a first pairof flex arms 246 and 248 are positioned on one side of the cradle 242and a second pair of flex arms 250 and 252 are positioned on the otherside of the cradle 242. As best seen in FIG. 7, the first pair of flexarms 246 and 248 reach overtop of the recess 244 and are bent inwardlyso that the rod 242 may be thrust into the recess by deflecting the flexarms 246 and 248 outwardly, then the flex arms restore themselves to theposition of FIGS. 6 and 7 in which the flex arms will block the rodagainst removal. The flex arms 250 and 252 are similar in constructionand operation. A suitable alternative structure for the rod guide 240 isshown in U.S. Pat. No. 5,074,676.

The molded panel 12 also includes integrally molded armrest supports260, 262 and 264. The armrest support 260 is molded integral with thecenter spoke 24 and reaches several inches inboard therefrom. Anintegral flange 268 depends downwardly from the underside from thesupport 260 to stiffen the support 262 against flexure when the armrestis suitably mounted to the armrest support 260 and bears occupant weightpushing downwardly. Likewise, the armrest support 262 is supported frombeneath by a gusset 270. The armrest support 264 is stiffened andstrengthened by a stub spoke 272 which projects down from the upperspoke 18 and is integrally molded with the armrest support 264.

As best seen in FIG. 1, the mounting panel 12 has a plurality ofintegral mounting brackets, including bracket 276 integral with spoke22, bracket 278 integral with spoke 26, bracket 280 integral withvertical spoke 21, bracket 282 integral with spoke 20. Each of thesebrackets has a aperture therein through which a screw or other suitablefastener may be installed to attach to the door hardware module of FIG.1 to the vehicle door structure. In addition, a pair of mountingapertures 284 and 286 are provided in the handle mounting plate forreceiving additional fastening screws.

Thus it is seen that the invention provides a new and improved doorhardware module including a one piece molded plastic panel comprised ofa plurality of spaced apart tubular spokes extending between spacedapart window guide channels.

It will be understood that the person of ordinary skill in the art maymake modifications to the invention within the scope of the appendedclaims. For example, the window guide channels 14 and 16 need not beintegrally molded with the spokes, but may be separate plastic or metalguide strips suitably attached to the ends of the spokes of the mountingpanel. In addition, the central mounting plate 50 is provided as aconvenient mounting location for the window regulator, however, certainmotor vehicles applications may provide alternate mounting of the windowregulator and thereby obviate the need for providing a mounting platestructure integral with the molded plastic mounting panel. Additionally,the various integral snap tab arrangements proposed therein are merelyexemplary of the types of snap tabs arrangements which can be employedto mount door hardware such as lock rods, handles, and window regulatormotors.

These and other modifications to the invention may be made within theordinary skill of the art.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A mounting panel formounting a window and a window regulator in a vehicle door comprising:aone piece plastic molded member having a planar mounting plate formounting the window regulator and a plurality of spaced apart hollowtubular spokes molded integrally with the planar mounting plate andradiating generally forward and rearward therefrom for mounting at leastone guide channel receiving an edge of the window.
 2. A mounting panelfor mounting a window and a window regulator in a vehicle doorcomprising:a one piece plastic molded member having a planar mountingplate for mounting a window regulator lift device, a plurality of spacedapart hollow tubular spokes molded integrally with the planar mountingplate and extending generally rearward therefrom for mounting at leastone guide channel to receive an edge of the window.
 3. A mounting panelfor mounting hardware in a vehicle door comprising:a one piece plasticmolded member having a substantially planar mounting plate and aplurality of spaced apart hollow tubular spokes molded integrally withthe substantially planar mounting plate and radiating therefrom formounting at least one window guide channel; and a window lift mechanismmounted on the substantially planar mounting plate.